Sealable bag having an integrated timer/sensor for use in vacuum packaging

ABSTRACT

A vacuum bag comprises a first panel and a second panel, wherein each panel comprises a gas-impermeable base layer and a heat-sealable inner layer with at least one panel having a timer and/or sensor embedded or encapsulated by the inner layer. The timer and/or sensor can be used to monitor storage time, contents, and/or the condition of packaged products, or can be used to protect contents. This description is not intended to be a complete description of, or limit the scope of, the invention. Other features, aspects, and objects of the invention can be obtained from a review of the specification, the figures, and the claims.

PRIORITY CLAIM

This application claims priority to the following U.S. ProvisionalPatent Application:

U.S. Provisional Patent Application No. 60/452,157, entitled “SEALABLEBAG HAVING AN INTEGRATED TIMER/SENSOR FOR USE IN VACUUM PACKAGING,” byHenry Wu, et al., filed Mar. 5, 2003 (Attorney Docket No.TILA-01182US0).

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This U.S. Patent Application incorporates by reference all of thefollowing co-pending applications:

U.S. Provisional Patent Application No. 60/452,168, entitled“LIQUID-TRAPPING BAG FOR USE IN VACUUM PACKAGING,” by Henry Wu, et al.,filed Mar. 5, 2003 (Attorney Docket No. TILA-01177US0);

U.S. Provisional Patent Application No. 60/452,138, entitled “METHOD FORMANUFACTURING LIQUID-TRAPPING BAG FOR USE IN VACUUM PACKAGING,” by HenryWu, et al., filed Mar. 5, 2003 (Attorney Docket No. TILA-01177US1);

U.S. Provisional Patent Application No. 60/452,172, entitled “SEALABLEBAG HAVING AN INTEGRATED TRAY FOR USE IN VACUUM PACKAGING,” by Henry Wu,et al., filed Mar. 5, 2003 (Attorney Docket No. TILA-01178US0);

U.S. Provisional Patent Application No. 60/452,171, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED TRAY FOR USE IN VACUUMPACKAGING,” by Henry Wu, et al., filed Mar. 5, 2003 (Attorney Docket No.TILA-01178US1);

U.S. Provisional Patent Application No. 60/451,954, entitled “SEALABLEBAG HAVING AN INDICIA FOR USE IN VACUUM PACKAGING,” by Henry Wu, et al.,filed Mar. 5, 2003 (Attorney Docket No. TILA-01179US0);

U.S. Provisional Patent Application No. 60/451,948, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INDICIA FOR USE IN VACUUMPACKAGING,” by Henry Wu, et al., filed Mar. 5, 2003 (Attorney Docket No.TILA-01179US1);

U.S. Provisional Patent Application No. 60/452,142, entitled “SEALABLEBAG HAVING AN INTEGRATED ZIPPER FOR USE IN VACUUM PACKAGING,” by HenryWu, et al., filed Mar. 5, 2003 (Attorney Docket No. TILA-01180US0);

U.S. Provisional Patent Application No. 60/452,021, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED ZIPPER FOR USE INVACUUM PACKAGING,” by Henry Wu, et al., filed Mar. 5, 2003 (AttorneyDocket No. TILA-01180US1);

U.S. Provisional Patent Application No. 60/451,955, entitled “SEALABLEBAG HAVING AN INTEGRATED VALVE STRUCTURE FOR USE IN VACUUM PACKAGING,”by Henry Wu, et al., filed Mar. 5, 2003 (Attorney Docket No.TILA-01181US0);

U.S. Provisional Patent Application No. 60/451,956, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED VALVE STRUCTURE FORUSE IN VACUUM PACKAGING,” by Henry Wu, et al., filed Mar. 5, 2003(Attorney Docket No. TILA-01181US1);

U.S. Provisional Patent Application No. 60/452,139, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED TIMER/SENSOR FOR USEIN VACUUM PACKAGING,” by Henry Wu, et al., filed Mar. 5, 2003 (AttorneyDocket No. TILA-01182US1);

U.S. patent application Ser. No. 10/169,485, entitled “METHOD FORPREPARING AIR CHANNEL EQUIPPED FILM FOR USE IN VACUUM PACKAGE,” filedJun. 26, 2002;

U.S. patent application Ser. No. ______, entitled “LIQUID-TRAPPING BAGFOR USE IN VACUUM PACKAGING,” Attorney Docket No. TILA-01177US2, filedconcurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING LIQUID-TRAPPING BAG FOR USE IN VACUUM PACKAGING,” AttorneyDocket No. TILA-01177US3, filed concurrently;

U.S. patent application Ser. No. ______, entitled “SEALABLE BAG HAVINGAN INTEGRATED TRAY FOR USE IN VACUUM PACKAGING,” Attorney Docket No.TILA-01178US2, filed concurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED TRAY FOR USE IN VACUUMPACKAGING,” Attorney Docket No. TILA-01178US3, filed concurrently;

U.S. patent application Ser. No. ______, entitled “SEALABLE BAG HAVINGAN INDICIA FOR USE IN VACUUM PACKAGING,” Attorney Docket No.TILA-01179US2, filed concurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INDICIA FOR USE IN VACUUMPACKAGING,” Attorney Docket No. TILA-01179US3, filed concurrently;

U.S. patent application Ser. No. ______, entitled “SEALABLE BAG HAVINGAN INTEGRATED ZIPPER FOR USE IN VACUUM PACKAGING,” Attorney Docket No.TILA-01180US2, filed concurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED ZIPPER FOR USE INVACUUM PACKAGING,” Attorney Docket No. TILA-01180US3, filedconcurrently;

U.S. patent application Ser. No. ______, entitled “SEALABLE BAG HAVINGAN INTEGRATED VALVE STRUCTURE FOR USE IN VACUUM PACKAGING,” AttorneyDocket No. TILA-01181US2, filed concurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED VALVE STRUCTURE FORUSE IN VACUUM PACKAGING,” Attorney Docket No. TILA-01181US3, filedconcurrently;

U.S. patent application Ser. No. ______, entitled “METHOD FORMANUFACTURING A SEALABLE BAG HAVING AN INTEGRATED TIMER/SENSOR FOR USEIN VACUUM PACKAGING,” Attorney Docket No. TILA-01182US3, filedconcurrently.

FIELD OF THE INVENTION

The present invention relates to bags for use in vacuum packaging andmethods and devices for manufacturing bags for use in vacuum packaging.

BACKGROUND

Methods and devices for preserving perishable foods such as fish andmeats, processed foods, prepared meals, and left-overs, andnon-perishable items are widely known, and widely varied. Foods areperishable because organisms such as bacteria, fungus and mold grow overtime after a food container is opened and the food is left exposed tothe atmosphere. Most methods and devices preserve food by protectingfood from organism-filled air. A common method and device includesplacing food into a gas-impermeable plastic bag, evacuating the air fromthe bag using suction from a vacuum pump or other suction source, andtightly sealing the bag.

A bag for use in vacuum packaging can consist of a first panel andsecond panel, each panel consisting of a single layer of heat-sealable,plastic-based film (for example, polyethylene). The panels are sealedtogether along a substantial portion of the periphery of the panels byheat-sealing techniques so as to form an envelope. Perishable products,such as spoilable food, or other products are packed into the envelopevia the unsealed portion through which air is subsequently evacuated.After perishable products are packed into the bag and air is evacuatedfrom the inside of the bag, the unsealed portion is heated and pressedsuch that the panels adhere to each other, sealing the bag.

U.S. Pat. No. 2,778,173, incorporated herein by reference, discloses amethod for improving the evacuation of air from the bag by formingchannels in at least one of the panels with the aid of embossingtechniques. Air escapes from the bag along the channels duringevacuation. The embossing forms a pattern of protuberances on at leastone of the panels. The protuberances can be discrete pyramids,hemispheres, etc., and are formed by pressing a panel using heatedfemale and male dies. The first panel is overlaid on the second panelsuch that the protuberances from one panel face the opposite panel. Thecontacting peripheral edges of the panels are sealed to each other toform an envelope having an inlet at an unsealed portion of theperiphery. The perishable or other products are packed into the envelopethrough the inlet, and the inlet is sealed. Thereafter, an opening ispierced in a part of the panel material that communicates with thechannels, air is removed from the interior of the envelope through thechannels and opening, and the opening is sealed. This type of bagrequires two additional sealing steps after the perishable or otherproduct is packed into the envelope. One further problem is thatembossing creates impressions on the plastic such that indentations areformed on the opposite side of the panel

To avoid additional sealing steps, a vacuum bag is formed having a firstpanel and a second panel consisting of laminated films. Each panelcomprises a heat-sealable inner layer, a gas-impermeable outer layer,and optionally, one or more intermediate layers. Such a bag is describedin U.S. Pat. No. Re. 34,929, incorporated herein by reference. At leastone film from at least one panel is embossed using an embossing mold toform protuberances and channels defined by the space betweenprotuberances, so that air is readily evacuated from the vacuum bag.

U.S. Pat. No. 5,554,423, incorporated herein by reference, disclosesstill another bag usable in vacuum packaging. The bag consists of afirst and second panel, each panel consisting of a gas-impermeable outerlayer and a heat-sealable inner layer. A plurality of heat-sealablestrand elements are heat bonded at regular intervals to the inner layerof either the first panel or the second panel. The spaces between strandelements act as channels for the evacuation of air. The strand elementsare extruded from an extrusion head and heat bonded to the heat-sealablelayer by use of pressure rolls. Separate equipment is required forproducing strand elements, and a procedure of heat bonding a pluralityof strand elements at regular intervals to the heat-sealable inner layeris complicated. Also, various shapes of pattern are hard to form usingthis process.

BRIEF DESCRIPTION OF THE FIGURES

Further details of embodiments of the present invention are explainedwith the help of the attached drawings in which:

FIG. 1A is a perspective view of a method for manufacturing a vacuum bagin accordance with one embodiment of the present invention;

FIG. 1B is a side view of the method shown in FIG. 1A illustrating theembossing method used in an embodiment of the present invention;

FIG. 1C is a close-up view of a portion of FIG. 1B;

FIG. 2 is a plan view of an exemplary timer/sensor on a panel inaccordance with embodiments of the present invention, manufactured bythe process shown in FIGS. 1A-1C;

FIG. 3 is a cross-section of a portion of a panel as illustrated in FIG.2, according to an embodiment of the present invention; and

FIG. 4 is a perspective view of a vacuum bag in accordance with oneembodiment of the present invention.

DETAILED DESCRIPTION

FIGS. 1A-1C illustrate one embodiment of a method for manufacturing avacuum bag in accordance with the present invention. The vacuum bagcomprises a first panel and a second panel, wherein each panel comprisesa gas-impermeable base layer 108 and a heat-sealable inner layer 106with at least one panel having a timer and/or sensor embedded inside thevacuum bag. A laminating roll 102 and a cooling roll 104 are arranged sothat the heat-sealable inner layer 106 can be laminated to thegas-impermeable base layer 108 as the melt-extruded resin is cooled. Asillustrated in FIG. 1C, the gap between the laminating roll 102 and thecooling roll 104 can be controlled according to specifications (forexample, thickness) of a panel for use in vacuum packaging. Thetemperature of the cooling roll 104 is maintained in a range such thatthe melt-extruded resin is sufficiently cooled to form the desiredpattern. For example, a temperature range of about −15° C. to about −10°C. can be sufficient to properly form the desired pattern. Thetemperature range of the cooling roll 104 can vary according to thecomposition of the resin, the composition of the gas-impermeable baselayer 108, environmental conditions, etc. and can require calibration.Also, the cooling roll 104 can be sized to have a larger diameter thanthe laminating roll 102, thereby bringing the melt-extruded resin intocontact with more cooled surface area. For example, the diameter of thecooling roll 104 can be about one-and-a-half to about three times aslarge (or more) as that of the laminating roll 102.

The heat-sealable inner layer 106 typically comprises a thermoplasticresin. For example, the melt-extruded resin can be comprised ofpolyethylene (E) suitable for preserving foods and harmless to a humanbody. A vacuum bag can be manufactured by overlapping two panels suchthat the heat-sealable inner layers 106 of the two panels can be broughtinto contact and heat can be applied to a portion of the periphery ofthe panels to form an envelope. The thermoplastic resin can be chosen sothat the two panels strongly bond to each other when sufficient heat isapplied.

The gas-impermeable base layer 108 is fed to the gap between the coolingroll 104 and the laminating roll 102 by a feeding means (not shown). Thegas-impermeable base layer can be comprised of polyester, polyamide,ethylene vinyl alcohol (EVOH), nylon, or other material having similarproperties and capable of being used in this manufacturing process, andalso capable of being heated. The gas-impermeable base layer 108 canconsist of one layer, or two or more layers. When employing amultilayer-structured base layer, it should be understood that a totalthickness thereof is also adjusted within the allowable range for thetotal gas-impermeable base layer 108.

An extruder 110 is positioned in such a way that the melt-extruded resinis layered on the gas-impermeable base layer 108 by feeding themelt-extruded resin to the nip between the cooling roll 104 and thegas-impermeable base layer 108. The resin is fed through a nozzle 112 ofthe extruder 110. The temperature of the melt-extruded resin isdependent on the type of resin used, and can typically range from about200° C. to about 250° C. The amount of resin to be extruded into thelaminating unit 100 is dependent on the desired thickness of theheat-sealable inner layer 106.

A pattern fabricated on the circumferential surface of the cooling roll104 in accordance with one embodiment of the present invention caninclude cavities for suspending timers and/or sensors for encapsulationby melt-extruded resin. Timers and/or sensors 124 can be seeded incavities of the cooling roll 104, for example by a label machine 114attached to the extruder 110. The resin melt-extruded by the nozzle 112is pressed between the cooling roll 104 and the gas-impermeable baselayer 108 and flows into the cavities of the cooling roll 104 andsurrounds the timers and/or sensors. The timer and/or sensor can be anydevice capable of communicating information to a user. For example,active radio frequency identification tags (RFID), such as the PowerIDSmart Active Labels (SAL) system manufactured by Power Paper Ltd. ofIsrael, contain batteries and can be used as disposable timers. Sensorssuch as the PowerID SALs can be user activated, are thin and flexible,and low-cost, while at the same time are non-toxic in case of packagepenetration. Alternatively, the timer and/or sensor can be connectedwith the gas-impermeable base layer 108, for example by adhesives,before the gas-impermeable base layer 108 is fed to the cooling roll104, thereby eliminating the need for cavities of the cooling roll 104.Alternatively, the sensor can be a temperature sensor having chemistrythat can change color if exposed to specific temperatures for prolongedperiods of time. In this way a user can estimate the freshness ofpackaged foods or other degradable products. The resin quickly cools andsolidifies with the timer and/or sensor impregnated or embedded in theresin, while adhering to the gas-impermeable base layer 108, therebyforming the heat-sealable inner layer 106 of the panel. Theheat-sealable inner layer 106 can be formed while the resin issufficiently heated to allow the resin to flow, thereby molding theresin, unlike other methods adopting a post-embossing treatment wherethe heat-sealable inner layer is drawn by a die or embossed between maleand female components.

In other embodiments, chemicals such as silver chloride or silverhalide, for example, can be added to the melt-extruded resin such thatmolecules of the chemicals are transparent to visible light in theabsence of UV light (such as artificial light), thereby allowing theuser to view the contents. When exposed to UV rays, as in directsunlight, the molecules undergo a chemical process that causes them tochange shape. The new molecular structure absorbs portions of thevisible light, causing the film to darken. The number of molecules thatchange shape varies with the intensity of the UV rays. In this manner,contents of the vacuum bag can be protected from the harmful effects ofUV rays. A laminated film formed by the heat-sealable inner layer 106and gas-impermeable base layer 108 can be fed to a second cooling roll(not shown) for adding a second inner layer, thereby forming a barrierbetween the impregnated resin material and the packaged product.

In other embodiments, chemicals such as potassium permanganate, forexample, can be added to the melt-extruded resin such that products thatcan spoil in the presence of ethylene can be preserved for a longerperiod as the ethylene is absorbed by the impregnated layer. A laminatedfilm formed by the heat-sealable inner layer 106 and gas-impermeablebase layer 108 can be fed to a second cooling roll for adding a secondinner layer, thereby forming a barrier between the impregnated resinmaterial and the packaged product that prevents chemicals from leachinginto the product, while allowing ethylene gas to be absorbed through thebarrier. One of ordinary skill in the art can appreciate the myriaddifferent ways in which timers and/or sensors can be added to a vacuumbag.

FIG. 2 is a plan view of a panel 220 formed by the cooling roll 104 foruse in a vacuum bag, in which the heat-sealable inner layer 106 ismolded in such a way that a timer/sensor 124 is embedded in theheat-sealable inner layer 106. The timer/sensor 124 can be activated tomeasure the amount of time a product has been packed or stored.Optionally, a second timer/sensor 226 can be embedded in theheat-sealable inner layer 106 such that the temperature of the bag canbe monitored. One of ordinary skill in the art can appreciate thedifferent methods for monitoring the vacuum bag and the contents of thevacuum bag.

FIG. 3 is a cross-section of a portion of a panel 220 in accordance withone embodiment of the present invention. The heat-sealable inner layer106, can range, for example, from about 0.5-4.0 mils in thicknessbetween timers and/or sensors, while the gas-impermeable base layer 108can range, for example, from about 0.5-8.0 mils in thickness. A secondheat-sealable inner layer optionally added, can add an additional0.5-4.0 mils in thickness.

The features and structures described above can be combined with othermanufacturing techniques to form a valve or other structure, or tray, asdescribed in the cross-referenced provisional applications, incorporatedherein by reference. In other embodiments, the circumferential surfacesof the cooling rolls 104 described above can optionally includeprotuberances for forming perforations (not shown), such that a bag canbe separated from a roll of bags by a customer.

FIG. 4 illustrates a bag for use in vacuum packaging in accordance withone embodiment of the present invention. The vacuum bag 450 comprises afirst panel 220 and a second panel 422 overlapping each other. A timerand/or sensor is formed on the first panel 220 in accordance with anembodiment described above. The second panel 422 (or first panel 220)optionally includes channels (not shown) along a portion of the panelfor evacuating air and other gases from the bag. The channels can beformed, for example, as described in the cross-referenced application“LIQUID-TRAPPING BAG FOR VACUUM PACKAGING,” incorporated herein byreference. The heat-sealable inner layer 106 and the gas-impermeablebase layer 108 of the first and second panels 220,422 are typically madeof the same material respectively, but can alternatively be made ofdifferent materials that exhibit heat-sealability and gas-impermeabilityrespectively. As described above, the heat-sealable inner layer 106 isused as an inner layer and the gas-impermeable base layer 108 is used asan outer layer. The lower, left, and right edges of the first and thesecond panel 220,422 are bonded to each other by heating, so as to forman envelope for receiving a perishable or other product to be vacuumpackaged. Once a perishable or other product is placed in the vacuum bag450, air and/or other gases can be evacuated from the bag 450, forexample by a vacuum sealing machine as described in U.S. Pat. No.4,941,310, which is incorporated herein by reference. Once the airand/or other gases are evacuated to the satisfaction of the user, theinlet can be sealed by applying heat, thereby activating theheat-sealable inner layers 106 and bonding them together.

The foregoing description of preferred embodiments of the presentinvention has been provided for the purposes of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise forms disclosed. Obviously, many modificationsand variations will be apparent to the practitioner skilled in the art.The embodiments were chosen and described in order to best explain theprinciples of the invention and its practical application, therebyenabling others skilled in the art to understand the invention forvarious embodiments and with various modifications that are suited tothe particular use contemplated. It is intended that the scope of theinvention be defined by the following claims and their equivalence.

1. A bag adapted to receive an article, comprising: a first paneldefining at least one molded portion; a second panel; and the firstpanel and the second panel secured together to form the bag; wherein theat least one molded includes at least one of a timer and a sensor.
 2. Abag adapted to receive an article, comprising: a first panel having: afirst outer layer; and a first inner layer connected with the firstouter layer, the first inner layer including at least one of a timer anda sensor integrally formed with the first inner layer; and a secondpanel connected with the first panel such that the first panel and thesecond panel form an envelope having an inlet, the second panel having:a second outer layer; and a second inner layer connected with the secondouter layer.
 3. The bag of claim 2, wherein the first outer layer andthe second outer layer comprise a gas-impermeable material.
 4. The bagof claim 3, wherein the gas-impermeable material is one of polyester,polyamide, ethylene vinyl alcohol, and nylon.
 5. The bag of claim 2,wherein the first inner layer and the second inner layer comprise athermoplastic resin.
 6. The bag of claim 5, wherein the thermoplasticresin is polyethylene.
 7. The bag of claim 2, wherein the first innerlayer includes at least one timer.
 8. The bag of claim 7, wherein the atleast one timer is an active radio frequency identification tag.
 9. Thebag of claim 2, wherein the first inner layer includes at least onesensor.
 10. The bag of claim 9, wherein the at least one sensor is atemperature sensor.
 11. The bag of claim 9, wherein the at least onesensor is a temperature sensor.
 12. The bag of claim 2, wherein thefirst inner layer includes UV activated chemicals.
 13. The bag of claim12, wherein the UV activated chemical is one or both of silver chlorideand silver halide.
 14. The bag of claim 2, wherein the first inner layerincludes at least one chemical for preserving the article.
 15. The bagof claim 14, wherein the chemical is potassium permanganate.
 16. A bagadapted to receive an article, comprising: a first panel including: afirst gas-impermeable layer; and a first inner layer laminated to thefirst gas-impermeable layer, the first inner layer having at least oneof a timer and a sensor; a second panel including: a secondgas-impermeable layer; and a second inner layer laminated to the secondgas-impermeable layer; and wherein the first panel is connected with thesecond panel to form an envelope such that the first inner layer opposesthe second inner layer, the envelope including a heat-sealable openingfor evacuating gas.
 17. A heat-sealable bag adapted to receive anarticle, comprising: a first panel including: a first gas-impermeablelayer; at least one first intermediate layer connected with the firstgas-impermeable layer; and a first inner layer laminated to the at leastone first intermediate layer, the first inner layer having at least oneof a timer and a sensor; and a second panel including: a secondgas-impermeable layer; at least one second intermediate layer connectedwith the second gas-impermeable layer; and a second inner layerlaminated to the at least one second intermediate layer; wherein thefirst panel is connected with the second panel to form an envelope suchthat the first inner layer opposes the second inner layer, the envelopeincluding a heat-sealable opening for evacuating gas.
 18. The bag ofclaim 17, wherein the first gas-impermeable layer and the secondgas-impermeable layer comprise one of polyester, polyamide, ethylenevinyl alcohol, and nylon.
 19. The bag of claim 17, wherein the firstinner layer and the second inner layer comprise a thermoplastic resin.20. The bag of claim 19, wherein the thermoplastic resin ispolyethylene.
 21. The bag of claim 17, wherein the first inner layerincludes at least one timer.
 22. The bag of claim 21, wherein the atleast one timer is an active radio frequency identification tag.
 23. Thebag of claim 17, wherein the first inner layer includes at least onesensor.
 24. The bag of claim 23, wherein the at least one sensor is atemperature sensor.
 25. The bag of claim 23, wherein the at least onesensor is a temperature sensor.
 26. The bag of claim 17, wherein thefirst inner layer includes UV activated chemicals.
 27. The bag of claim26, wherein the UV activated chemical is one or both of silver chlorideand silver halide.
 28. The bag of claim 17, wherein the first innerlayer includes at least one chemical for preserving the article.
 29. Thebag of claim 28, wherein the chemical is potassium permanganate.
 30. Asystem for forming a bag including a three-dimensional structure formedon at least one panel, comprising: an implant including at least one ofa timer and a sensor; a cooling roll having one or more structures forpositioning the implant; a laminating roll; a backing material; and aflowable material that can be flowed into the one or more structures toenvelop the implant, the flowable material adhering to the backingmaterial.